ML20117F508

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Rev 6 to Procedure Pr 15.0, Nonconforming Matl or Items
ML20117F508
Person / Time
Site: Waterford Entergy icon.png
Issue date: 09/21/1982
From: Laporte W, Ronquillo R
GULF ENGINEERING CO., INC.
To:
Shared Package
ML20117F125 List:
References
FOIA-84-205 PR-15.0, NUDOCS 8505130271
Download: ML20117F508 (24)
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!!ATERF0FD SNAM ElICITtIC SIATION - UNIT NO. 3

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a PROCDURE TITLE:

NONQONFORMING MATERIAL OR EOCEM MER PR 15.0 ITEMS ~

-PAGE 1

OF 1

ISSUE

SUMMARY

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ISSUE /DATE PREPARED APROVID g REMARKS

///E 1/8-16-78 R. M. R onquillo R. M. Ronquill This procedure: cancels and super-QA Manager sedes Procedure No. PR 14.0, Issue 8 dated 1/10/78, Same Title.

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2/11-29-78 R. M. Ronquillo R. M. Ronqu' o Revised Para. 4. 2, 4. 5 5.1.1, QA Manage 5.1. 2, 5. 4, 5. 5, 6. 4. 3.1, 6. 7.1, 6.12, 6.12.1 & 6.12.2, 6.12. 2.1 thru 6.12. 2. 3, 7.10 & 7.11.-

Added Para. 6,12.1 Deleted Para. 6.1.1. 3 & 6. 5

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3/7-19-79 W

odrigue R.M. Ronqu Revised Para. 5.4, 6.1, 6.1.1.3, Q. A. Engineer Q. A. Manager and 7. 0.

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Added Para. 5.1.3, 6.1.1.4, 6.1.1.5, g

6. 2.1, 6. 2. 2,.6. 2. 3, 6. 2. 3.1,' and h.g.[g g

--Porm No. PR 15. 0-11.

4/1-27-81 R. B. Constable R. M. Rong ' o Revised Para. 4. 2, 6. 4.1,. 6. 4. 3.1, Q. A. Engineer Q. A. Manager and 6. 8. 2

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Lapo rte R. M. Ronquillo Deleted Paragraph 6.2.3.1 & 6.2.2, Q.A. Engineer Q '. A. Manager Attachment No. 7.12 W.P.. du:. E M#A"/

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R. M.Ronquillo Added Paragraph 6. 9.2 and. Attach-Q. A. Manager [

6/9-21-82 W.R. Laporte ment No. 7.12 Q. A. Engineer o

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(;hy t.. J Dre 6 ik., ca., iM Contract. W3-NY-5 WATERFORD STZAM ELECI"AIC STATION - UNIT No. 3 ISSUE: 6 TITLE: Nonconforming Material PROCEDURE NUMBER:

PR 15. 0 or Items PAGE 1

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1. 0 PURPOSE 1.1 Itis the purpose of this procedure to establish a system for the identification, documentation, segregation, review and disposi tion of all no'nconforming material or items.
2. 0 SCOPE 2.1 This procedure applies to all permanent material or items, or measuring and test equipment and/or associated documentation determined to be nonconforming during receiving, inspection, handling, storage, installation and related activities at the construction site.

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3. 0 REFERENCES 3.1 Gulf Engineering Company, Inc. Nuclear Quality Assurance Manual
3. 2 Ebasco Procedure No. ASP-III Nonconformances

- "- - 3. 3 10CFR50, Appendix B - Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants.

3. 4 ANSI N45.2 - Quality Assurance Program Requirements for Nuclear Power Plants
3. 5 Ebasco Procedure No. ASP-III Corrective Action
3. 6 ASME Boiler and Pressure Vessel Code - Section III, Division I 4.0 DEFINITIONS 4.1 Authorized Nuclear Inspector (ANI) - An inspector employed by an Authorized Inspection Agency who has been qualified by written examination under the rules of any State of the United States or Province of Canada which has adopted the Code and who meets the
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WA*d -SO.<D STE.*f4 E!.U' F TC.e. "A'i lON - UIiIT i;o. 3

. ISSUE: 6 TITLE:

Nonconforming Material

-FROCEDURE I.U 3DI:

PR 15.0 or Items PAGE 2

OF n

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4, 2, Discrepancy A deviation from specified requirements (including procedures) that can be readily corrected in accordance with stan-dard approved operating procedures or specifications.

A few examples of discrepancies ares a)

Incomplete operations which can be completed with approved operating procedures.

,b)

Replacing missing components.

4. 3' Inspection - A documented phase of quall'ty control which.by means of examination, observation or measurement determines the con-formance of items or material to predetermined quality requirements.

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4. 4 Item Any level of unitsssembly, including structure, system, sub ~ assembly, sub-system, component, part or material. Items T

also include products manufactured under an ASME Certificate of Authorization.

.4.5 Nonconformance - A deficiency in characteristic, documentation, or procedure which renders the quality of an item unacceptable or

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indeterminate. Examples of nonconformances include: physical

@E defects, test failures, incorrect or inadequate documentation, or deviation from prescribed processing, inspection or test procedures.

The following are some examples of deviations from the applicable specifications, codes and standards that must be classified as nonconformance s:

a)

Deviations that affect the structural integrity of the item such as deviation in materials; deviation in nondestructive test requirements; deviations in welding, heat treating / stress relieving requirements. Deviations from parameters of stress-repor' ts; deviations in testing requirements and undersized steel reinforcing bars....

' b)

Deviations that are likely to result in failure or reduce materially 4

the usability of the item; such as, deteri' oration re sulting from

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inadequate storage; use of weHing filler metal other than th~ se o

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Code requirements; severe lo;alized corrosions and pipe bending

, ' radius smaller than that specified by the specification, j

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MATi?. FORD STEAM E!JCDIC SIMION - UNIT No. 3

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ISSUE: 6 TITLE:

Nonconforming Material or-FROCEDURE MR:3FR: -PR 15. 0 Items FAGE 3

OF 11

- NOTE: Nonconformance reports win not be generated for

, welds considered in process as a result of NDE provided repairs are made in accordance with

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--Procedure No. PR 11. 6 - Control of Production Z~

Welding.

4. 6 Owner - Louisiana Power and Light Company or its authorized agent.
4. 7

. Repair - The process of restoring a nonconforming characteris-tic to a condition such that the capability of an item to function reliably and safely is. unimpaired, even though that item stin may not conform to the original requirement.

4.8 Rework - The process by which a nonconformingditem is made to conform to a prior specified requirement by completion, remachin-ing, reassembling or other corrective means.

5. O R ESPONSIBILITIES 5.1 -

The. Quality Control Supervisor, or his designee, is responsible for the foHowing:

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5.1.1 Assure that nonconformances detected at the construction site by Gulf Engineering personnel, or reported by Owner representatives during surveinance inspection, are docu-mented on the nonconformance report form (Ebasco Form 6009-H) for safety-related items or Gulf Engineering Form No. PR 15.0-8 for non-safety relat'ed items. Discrepancie's detected shall be documented on a Discrepancy Report (Form No. PR 15. 0-9).

5.1. 2 Identify nonconforming or discrepant items by tagging as per this procedure.

5.1. 3 Provide quantity and location of Hold Tags and store tagged items in segregated storage areas as required. In addition,

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~ perform periodic inspections of tagged material to insure

.__. cessation of work on that material and to insure that hold.

- tags refrisin' attached'to the material until the nonconforming conditions are removed.

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  • A7GFORD STDJf EL:Cu1C S~ATION - tmrr I:0. 3 v

- ISSUE: 6 TITLE: -- Nonconforming-Material ROCEDURE IM3ER:

PR-15. 0 or items PAGE 4

OF H

5. 2 The Quality Assurance Manager and/or the Quality Control Super'-

, visor is responsible for issuing Stop Work Orders when in hi's

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judgement continuance.of work would be detrimental to the safe'ty of personnel-or would impair capacity of the item to function as intended.

5.3 The Construction Superintendent is responsible for having " Repair or Rework" dispositions performed and for returning material or items which are dispositioned to be disposed of or returned to manufacturer.

5.'4 The Quality Control Supervisor, or his designee,"shan be respon-sible for maintaining the Status of Nonconformance Reports (NCR),

Discrepancy Reports, Stop Work Orders (SWO), Work Release Orders (WRO), Monthly NCR Surveinance Reposts, and status tags, Status tags shan be checked periodicany while in field for condition o

of tag and missing tags.

5.5 The Quality Assurance Engineer shan review au nonconformances and descrepancies to determine if corrective action to prevent reoccurrence is required.

6. 0 PR OCEDURE 4 ;,

6.1 Au personnel of Gulf Engineering shall report conditions suspected of not conforming to C6de or. contract requirements to the Quality Control Supervisor. The Quality.Conirol Supervisor, or his designee, shan attach a Hold for QC Release tag (yellow) Form PR 15.0-3, to the item and initiate a nonconformance report in accordance with the fonowing paragraphs:

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6.1.1 The Quality Control Supervisor shan assign an identification number and enter it on the Nonconformance Report (Ebasco Form No. 6009-H) Attachment #7.2 for safety-related items or Gulf Engineering Form No. PR 15.0-8 for non-safety related items and also enter number and subject on the Status

, of Nonconformance Reports (Form No. PR 15.0-1) Attacht.

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-. Complete the portion of the report that identifies --

the material or items, system, drawing or docu-ment affected.

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L'ATIN C.;D NT.*J! EIACM1C F.W ION - UiiIT UO. 3 ISSUE:

6 TITLE:

Nonconformin[ Material 1ROCEDURE HU1GER:

Pit-15. 0 or,1tems PAGE 5

or 11 6.1.1. 2 C'omplete a description of the nonconforming condition.

6.1.1. 3 Indicate on the r,eport the number of hold tags applied to the nonconforming material and the location of each tag. If the hold tag (s) is moved from the position indicated, the new location of the tag (s) shan be entered onto the NCR by the Q.C. Supervisor.

6.1.1. 4 Indicate the ASME Class (either 1, 2, or 3) if applicable in the item description slot. In addi-tion, indicate the applicable, in the drawing number / specification number slot.

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6.1.1. 5 Sign and date this report in the space provided.

6. 2 The Quality Control Superviso'r shan determine if it is practical to segregate the nonconforming material or items from conforming material, and place in a designated " Hold Area".

When the material or items are to be segregated, the. Quality.. Control Supe'rvisor shall forward a copy of the nonconformance Report to the Construction Superintendent mr'.ed " Move to Nonconforming Hold Area". Upon j ?.

completion of the placement of the material or item in the " Hold Area", the Construction Superintendent. win sign and date his copy of the Nonconformance Report and return this to the Quality Control Supervisor. This copy win be filed with the nonconforming record for this material or item (s).-

e 6.2.1 In the case where the size and/or location of the items reported on the'Nonconformance Report prohibit the attach-ment of a hold tag, segregated s.torage areas shall be pro-vided using signs or roped-off areas.

6.2.2 Open Nonconformance Reports win be reviewed monthly and 1

j necessary inspections will be made to assure that hold tags

_., are appropriately applied to items and that missing tags

are replaced.

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WATD FCRD F i.".AM F.I.Fa*~~ri1C ETATION - UNIT 7:o. ~3

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ISSUE:-'6-TITLE:-- -Nonconforming -Mate rial FFOCEDURE IMGER:

PR_15. 0 or Items PAGE 6

OF U

6. 3-Within twenty (20) days from initiation of a Nonconformance Report, the Quality Control 5 spervi'sor, the Construction Superintendent, and the Quality Assurance Engineer (if required), shan determine the rec'ommended disposition of the nonconforming material or ite m. The recommended disposition shan be entered on Ebasco's Nonconformance Report, Form No. 6009.H, or Gulf Engineering's Form No. PR 15.0-8, Nonconformance Report --Non-Safety Related Items, (Attachment #7.9), and signed by au parties making

, disposition.

6.4 Recommended dispositions include accept-as-ie, repair, rework, reject, or return to supplier, as applicable.

6.4.1 ~ Accept As-Is: A disposition indicating thet the nonconformance 7'

does not adversely affect use of the item for. its intended purpose. On ASME Code items, an ' accept-as-is disposition is applicable only if the condition is within ASME Code requirements. This disposition must be s' bstantiated by u

reference to technical data or explanation to justify this 7,.

disposition and must be recorded on the Nonconformance

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6.4.2 Rewo rk: A disposition indicating that the nonconforming

?.; i item can, through subsequent remachining, reassembling, reporcessing or completion of the. required operations, be brought into conformance with original drawing and specifi-cation requirements.

6.4.3 Repair

A disposition indicating that the nonconforming characteristic ;can be resto' red to a condition such that the capability of the item to function reliably and safely is unimpaired even though that item stin may not conform to the original requirement. The end product for Code items -

A after repair shan satisfy Code requirements; Complete D.i,[

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f repair instructions, including post-repair accept / reject M.E f,.

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criteria and required records, must be recorded on the y" -

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"..... will be initiated per Procedure No. PR 10.0 to document.

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" the method and extent-of repair -and-for designation of Hold.'

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.. s..1 - 3 WATEMORD STEM 4 FT.ECTFIC STATJON - UNIT 'to. 3 ISSUE: 6 TITM. Nonconforming Material PROCEDURE NUMBDt:

RR 15. 0 or Items PAGE 7

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,. 6.4.3.1 Standard Repair: This disposition is used when it

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is determined that item (s) can be repaired in

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accordance with an approved Standard Repair I

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Procedure which win render the item (s) completely s.

functional and usable. The Standard Repair Pro-cedure number must be recorded on the Noncon-formance Report and the Repair Traveler.

, 6. 4. 4 Reiect:

A disposition indicating that the item is unsuitable

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for its intended purpose and economicany or physicany incapable of being reworked or repaired and wiu not be used on Code work.

6.4.5 Return to Supplier: This disposition is ufed when it is determined that the nonconforming items are to be returned to the supplier for credit, rework or replacement. Owner-furnished material will be returned to the Owner or his supplier as directed by the Owner.

6. 5 For safety related items, in the space provided for the recommended f

disposition on the Ebasco Nonconformance Report (Form No. 6009-H),

the Quality Assurance Engineer will make a note when corrective

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action is required to prevent recurrence.

6.5.1 When corrective action to prevent. recurrence is required, a Corrective Action Report, Form No. PR 16.0-1, win be prepared by the Quality ' Assurance Engineer and processed per Procedure No. PR 16.0 - Corrective Action.

' 6. 5. 2 The. Corrective Action Report number will be logged by the Quality Assurance Engineer,. adjacent to the note on the

_ r Nonconformance Report that required corrective action.

He win also initial and date the transaction.

' 6. 6 ~ For non-s'afety related items, the Quality Assurance Engineer wiu

  • . mark the appropriate block indicating whether corrective action is

( required to prevent recurrence.

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. y same procedure as outlined in paragraph 6. 5.1 and 6.5.2 win be followed for non-safety related items.

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-' ISSUE: 6 TITLE: -Nonconforming Material FRGCEDURE NUlGER:

PR.15 0.

or Items PAGE 8

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The nonconformance report with recommended disposition shan be forwarded to Ebasco's Quality Assurance Site Supervisor for safety related items or to Ebasco's Contract Administrator for non-safety i'~- ' ; related-iterns by the Quality Assurance Engineer,. No fuither. pro-

" cessing of the Nonconformance Report win occur until Ebasco returns the nonconformance with an approved disposition.

6. 8 Upon return of the nonconformance report from the Owner with an j

approved disposition, the required corrective action, when required,

, win be performed and documented within twenty (20) working days, unless otherwise approved by the Owner, as fonows:

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'6.8.1 For safety related items, Ebasco's nonconformance report

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win be used to document corrective action taken and vem.

fication of same.

E 6.8.2 For ASME Code items,.the nonconformance win be routed to the Authorized Nuclear Inspector (ANI) by the Q. C.

Supervisor for concurrence of the approved disposition.

His concurrence win be documented by signature and date on the nonconformance.

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'6. 8. 3 For non-safety related items, the Gulf Engineering noncon-J J formance ~ report, Form No.PR 15.0-8 (Attachment #7. 9) 1 win be used to document corrective action taken and veri-fication of same.

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t 6.8.4 If deemed necessary, ai Traveler win be u.=ed for docurnenting and verifying repair / rework instructions and win supplement Ebasco's or Gulf Engineering's Nonconformance Report.

i 6.8.4.1 The. Traveler shan include the inspections necessary to verify that the material or item (s) i has been restored to acceptable condition. For processing of the Traveler, see Procedure No.

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s f 6. 9 ' lThe' Quality Control Supervisor, 'or his designee, shan sign the

,(. '. Gulf Engineering nonconformance report or the Ebasco nonconfor -

.mance report to verify ac'ceptance of corrective action taken, remove the " Hold for QC Release" tag (yeHow) from the material 9

or item, place an " Accepted" tag (green), Form No. PR 15.0 -

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.G T AT.% FORD SWU! EISC'.n IC STATION - UNIT NO. 3

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ISSUE: 6 7ITLE:

Nonconforming' Material FMCEDUREMGER: - PR 15_. 0 -

or Items PAGE 9

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(Attachment #7.5) on the material or item if it is in warehouse storage, and stamp the " Status of Nonconformance Reports Log".

-- c--Ebasco Quality Assurance win be notified of completion of. dis-position of safety-related nonconformances by returning the signed

' copy of the nonconformance report.

Copies of completed nonconformance reports will be sent to the Authorized. Nuclear Inspector (ANI) for concurrence of au Code

, items dispositioned repair, rework, or use-as-is. His concurr-ence will be documented by signature and date on the nonconformance and returned to the Quality Control Supervisor.

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-6.9.1 If.the material or item is.not in warehouse storage, the'

" Accepted" tag (green) is not required. i

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6.9.2 When a Safety Related Nonconformance affects more than one (1) Start-up System, a partial closure by Start-up System-can be accomislished by using Attachment No. 7.12. The Construction Superintendent, or his designee, will fill in 6

- the Corrective Action block and sign and date same. The H

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---.. - Q.C. Supervisor wiu list attachments, sign and state which will signify his acceptance of partial closure for the Start-up System listed. The O.C. Supervisor win then transmit 4

the form to Ebasco Quality Assurance with Attachments. A copy of the Partial Closure Form.will be filed with the nonconfoimance. -

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V 6.10 When the disposition of nonconforming mate ial or item (s) is to -

reject or wturn to supplier, the " Hold for Q. C. Release" tag (yellow) Form No. PR;15.0-3 (Attachment #7.1) shall be removed and a REJECT tag (red) Form.No. PR 15.0 4 (Attachment #7.4),.

shan be affixed to the material or item (s). This mateital or item (s),

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- where practical, shan be placed in a designated area appropriately marked by red lines and easily discernible signs. As directed by (j

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. the Owner, the material or item (s) win then be re' turned to the S&

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., qOwner to be disposed of or returned to the supplier.

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" 6.10.1 When it is necessary to return nonconforming ma~terial or.

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.... c.,.'-an item to the= Owner-due to a REJECT cr R ETURN TO j -
.zl SUPPLIER disposition, the-nonconformance report will be i,. ;

stamped by the. Quality Control Supervisor, or his designee,

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with a'" Return to Owner"' stamp (Attachment #7. 8). The

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WATDU'ORD STEAM Fl.ECA'I<IC STATION - UNIT 70. 3

. ISSUE: 6

'TITII:'...Non c onforming. Mat e r ial 50CHIRE 1MGER:

PR-15. 0 or Items PAGE 10 OF

....__. H stamp win be signed by the Construction SupeMatendent,

. signifying that the item or material was recurned, and by 1

.- the Owner's representative receiving the item or material.

7"-* 'The stamped copy of the nonconformance-report win be

-- ^Tu filed by the Quality Control Supervisor.

6.n Where the quality of items or services is not satisfactory, and it is deemed necessary by the Quality Assurance Manager or the Quality Control Supervisor, a Stop Work Order, Form No. PR 15.0-6, (Attachment #7.6) may be issued to the Project Manager. The

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Stop Work Order win stop any job or any portion of a job. The work stopped shan only be resumed upon a Work Release Order {

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Form No. PR 15.0-7 (attachment #7.7) from the Quality Assurance Manager or the Quality Control Supervisor. This work Release Order win show specific reference to the Stop Work Order number

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previously implemented..

6.12 A discrepancy as defined in Para. 4.2 will be documented on a Discrepancy. Report, Form No. PR 15. 0-9 (Attachment #7.10) by QC inspection personnel.

6~.12.1..The QC Supervisor win-review all discrepancy. reports to determine whether or not they should be reported a's a u

e nonconformance. If determined to be a nonconformance, Y

he wiu have a nonconformance processed instead.

6.12.2 The Discrepancy Report win be handled the same as a non-safety related Nonconformance Report, j

6.12.2.1 The Discrepancy Report for both safety related and non-safety related items will be forwarded to Ebasco's Contract Administrator for an approved disposition or the Q A. Engineer win assign an approved disposition.

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on the Discrepancy Report Log. No further processing of the discrepancy report is required.

7. 0 ATTACHMENTS

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7.1 Hold for Q.C. Release Tag (yenow) - Form No.,PR 15.0-3 c.! :.

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7. 2 QuSUty Assurance Nonconformance Report - Ebasco Form 6009-11
7. 3 Sta62s of Nonconformance Reports - Form No. PR 15.0-1
7. 4 REJECT Tag (red) - Form No. PR 15. 0-4

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7. 5...

Accepted. Tag breen) - Form No. PR 15.0-5 7.6 ~

Stop Work Order - Form No. PR 15.0-6

7. 7 Work Release Order - Form No. PR 15.0.-7
7. 8

" Return to Owner" Stamp 7

7. 9 Nonconformance Report - Non-Safety Related Items - Form No.

- PR 15. 0-8 7.10-Discrepancy Report - Form No. PR 15.4-9

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7. 11-Discrepancy Report Log - Form No. PR 15.0-10
N-6-

7.1Z Nonconformance Report Partial Closure Form No. PR 15.0-11

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WATERTORD STEAM ELECTRIC'STA TION '- UNIT 3-C l. "

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. Partial corrective action on the subject Nonconformance Report has been completed as evidenced by the corrective action statement provided below. Please provide g

this information to the app, late N=m OA Discipline Engineer for his varMW,j tien. I understand that this partial closure will not be effective nor removed f

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